The article formulates the task of synthesizing closed-circuit control systems for electric resistance furnaces (ERF) according to a complex criterion for minimizing energy costs and transient time in these systems. This quality criterion relatively fully takes into account the basic requirements for the functioning of ERF, which form a fairly wide class of control object (their number reaches up to 90 % of all electrothermal installations in the country), characterized by high energy consumption and inertia of processes. The optimal control problem uses a generally accepted mathematical model of ERF dynamics in the form of a transfer function describing the dependence of the temperature in the furnace (adjustable value) on the control action, which is the electric power released on the heating element. А method for solving it is proposed, which provides a significant reduction in energy costs when controlling the furnace in comparison with known methods, high accuracy of temperature control, as well as the possibility of taking into account restrictions on the values of the controlled value and control action. The method is based on the transformation of this quality criterion into a kind of generalized functional and the application of the theory of analytical design of optimal regulators by А. A. Krasovsky using the predictive model of free movement of ERF. The proposed energy-saving positional control algorithms allow for a relatively simple implementation using modern microprocessor control devices. An example of the synthesis of energy-saving feedback algorithms for a specific object is considered.
Fast, precise, and energy-efficient temperature control is essential for semiconductor vertical furnaces. In conventional configurations, a heater installed outside the process tube, referred to as the Main Heater, is relatively far from the temperature sensors near the wafers, resulting in slow thermal response and high energy consumption. To improve heat-transfer efficiency, this paper employs a heater installed inside the process tube, referred to as the Inside Heater, which is located close to the temperature sensors. However, since both the Main Heater and the Inside Heater act as heating actuators, their control inputs must be appropriately allocated while coordinating them with the Cooler. To address this issue, this paper proposes a three-actuator temperature control method based on virtual integrated heater-cooler control. The output of a single PID controller is separated by filters, assigning low-frequency heating components mainly to the Main Heater and high-frequency components to the Inside Heater. Switching logic is used to satisfy unilateral input constraints, i.e. the actuator inputs are constrained to be nonnegative, and suppress simultaneous heating and cooling. Experiments on a semiconductor vertical furnace show that the proposed method reduced energy consumption by 23.7% for a 390-400°C command compared with a Main Heater and Cooler method. These results demonstrate that the proposed filter-based task allocation efficiently utilizes the fast, low-power Inside Heater while retaining the heating capability of the Main Heater.
Koma Nishioka, Christian Milleneuve Budiono, Wataru Ohnishi et al.· 2026 IEEE/ASME International...· 0 citations
In the heating process of a regenerative heating furnace, furnace temperature is a crucial factor affecting the quality of steel billets. Given the inherent nonlinearity, uncertainty, and hysteresis of the heating process itself, it is difficult to achieve precise control of furnace temperature. Accurate prediction and regulation of furnace temperature are conducive to controlling product quality. Therefore, this paper proposes an optimized combustion control strategy for heating furnaces, which combines the Generalized Predictive Control (GPC) algorithm with an improved double cross-limiting control system. Firstly, for the temperature-rising stage, a GPC controller is designed, and the prediction horizon and control weight coefficients are optimized through offline simulation. This ensures the furnace temperature rises stably and avoids overshoot. Secondly, for the temperature-holding stage, the improved double cross-limiting control is adopted. A furnace temperature deviation feedback adjustment mechanism is introduced to optimize the upper and lower threshold values of the air-fuel ratio, thereby suppressing furnace temperature fluctuations caused by changes in combustion air flow during the stabilization process. Finally, a comparative experiment is conducted between this segmented control strategy, double closed-loop control, and double cross-limiting control. The results confirm that the proposed "GPC-improved double crosslimiting" control strategy can achieve efficient temperature control of the regenerative heating furnace. The system exhibits small control overshoot, fast control speed, and good stability, which meets the process requirements for steel billet heating.
Yingbao Zhao, Boxu Yao, Yonggang Sheng et al.· International Conference on...· 0 citations
The article discusses the development and application of induction heating systems in various industries, including agricultural machinery manufacturing, the automotive industry, and metal processing. A comparative analysis of induction installations and conventional heating methods is presented, highlighting their advantages such as high heating rates and efficiency, improved process control, and reduced energy consumption. The mathematical model of the frequency converter for induction heating systems is based on a system of discrete equations describing the dynamics of multidimensional variables. Unlike existing approaches, the proposed model takes into account the optimal operating frequency range, reduces the number of power transistors, and considers the installed power, thereby maintaining high energy efficiency. Within the scope of the study, a prototype frequency converter operating in the 2-20 kHz range with single-phase and three-phase power supply, as well as a 6 kW inductor, were designed and manufactured. Experimental studies confirmed the adequacy of the proposed model and its applicability under real technological conditions. The practical significance of the work lies in the possibility of using the developed model and prototype to select optimal induction heating technologies for mechanical engineering and agricultural machinery, ensuring increased reliability, reduced energy consumption, and lower operational costs. The results demonstrated the sufficiency of the proposed model and confirmed its practical applicability. onic components, which may affect both the converter operation and the power supply network. It was shown that variations in converter parameters have a significant impact on the selection of optimal induction heating modes, which is of practical importance for both educational purposes and industrial implementation.
A. Z. Sagyndykova, N. A. Zaetc, R. A. Zhamasheva et al.· Bulletin of Shakarim Univers...· 0 citations
This is an example of a paper that will provide a numerical simulation study on analytical solutions for optimal control of solar heat supply systems (SHSS). It will develop and solve a mathematical model for the “solar collector - storage tank” subsystem using a finite element technique and standard k-epsilon turbulence closure, derive an optimal pump speed control law for maximizing heat delivery to the storage tank, through a collection of output heat functions demonstrated as quadratic with respect to flow rate G
opt
for each instantaneous solar insolation level J, continuously determine G
opt
through algorithm methodology based on microcontroller maximum heat exchange outlet temperature and non-volatile “J-G” maps in memory for rapid response to non-stationary irradiance conditions. The simulation results demonstrated that the proposed strategy can achieve a seasonal thermal efficiency increase of 11-22 percentage points compared to conventional ON/OFF differential temperature control while increasing the pressure drop only 10.3%. In addition, the thermal-enhancement of peak Nusselt number (18.9%) and Performance Evaluation Criterion (1.15) indicates that there is a net thermohydraulic benefit to implementing the proposed strategies. The results of the study quantitively identify tuning of controllers and sizing of heat exchangers in residential and commercial solar installations.
Zhumakulov Zhoodarbek, Obozov Alaibek, Bekov Elmurat et al.· EPJ Web of Conferences· 0 citations
The article is aimed at studying the features of the hot rolling mill CWBRM-1700 of JSC “Qarmet”, which negatively affect the operation of the distribution network of the workshop. Such factors are frequent shock loads of technological mechanisms with high installed capacity of the equipment. Experimental studies of the distribution network of the rolling production on the buses of the 10 kV substation showed that shock loads of synchronous electric drives of roughing stands lead to periodic voltage drops of up to 13% lasting 5–6 s. Mathematical modeling in the MATLAB/Simscape/Electrical environment, the results of which coincide with the data of the experimental study, showed that the most significant factor affecting the quality of electricity are abrupt changes in the reactive power of the synchronous motor from −0.5 to +0.5 MVAR. To solve the problem, it is proposed to use a controlled filter-compensating device. Variants of circuit solutions for such devices are considered. The choice was made in favor of a three-phase adjustable LLC filter with diode–transistor keys. The article develops a method for calculating the electromagnetic parameters of such a filter and establishes that in order to reduce the level of harmonic distortion of voltage, it is necessary to use a triangle connection of the controlled reactive compensator and select the PWM frequency of the transistors, a multiple of the tripled frequency of the power grid. Two options for creating a closed-loop control system for energy modes are studied: a reactive power stabilization system and a voltage stabilization system in a distribution network node, which reduce the duration of transient processes to 0.5 s and reduce the voltage drop in the network node to −4 to + 1% in the first case and to −4 to + 3% in the second, also reducing reactive power consumption to 0.02 MVAR and 0.25 MVAR, respectively. The advantage of a closed-loop control system with voltage stabilization is the ability to use a technically less complex voltage sensor.
Arailym Smail, Alibek Batyrbek, K. Smagulova et al.· Engineer· 0 citations
The power supply system of reinforced
concrete plants is characterized by high energy consumption and is vital for the continuity
of the production process. Obsolete equipment, uneven load distribution, high reactive
power levels and limited automated controls
were identified as major problems in the current system. These problems lead to increased energy losses, rapid breakdown of equipment and production stoppages. Obsolescence of lighting systems and lack of automatic
adjustment systems increase additional energy consumption.
Failure to provide reactive power compensation leads to an increase in current and
heat losses on the network. The lack of accurate control of energy consumption reduces
the effectiveness of optimization measures.
Organization of the production process with
peak loads leads to the frequent tripping of
protective devices. In order to optimize the
power supply system, it is important to install
automatic capacitor banks, apply frequency
regulators, and replace outdated equipment
with efficient technologies.
Application of automated energy management systems ensures optimization of energy balance. When the system is updated step
by step, the risks of accidents are reduced,
maintenance costs are reduced to a minimum,
and the service life of the equipment is extended. As a result, the productivity of the plant
increases, energy consumption decreases and
economic indicators improve. Thus, the improvement of the electricity supply system is
of strategic importance in terms of both
energy saving and production stability and
competitiveness.
B. Q. Mehdiyev, P. E. Canbazov· Ekologiya və Su təsərrüfatı· 0 citations
